MCi Crusader II 1989 Maintenance Manual page 425

Date
1 • 1 -89
Page·~-__
1_3._22 _ _
MC-9 MAINTENANCE MANUAL.
TRANSMISSION PARTS INSPECTION
Before reassembling the transmission, the individual parts
should be carefully checked. Replace those damaged from
previous service. This inspection procedure should be care-
fully followed to ensure the maximum wear life from the rebuilt
unit.
1.
Wash all bearings in clean solvent. Check balls, rollers
and races for pits and spalled areas. Replace bearings which
are pitted or spalled.
2. Lubricate bearings which are not spalled or pitted and
check for axial and radial clearances. Replace bearings with
excessive clearances.
3. Check fits of bearings in case bores. If outer races turn
freely in the bores. the case should .be replaced.
4. Check operating gear teeth for pitting on the tooth faces.
Gears with pitted teeth should be replaced.
5. Inspect all engaging gear teeth. Gears with teeth torn.
tapered or reduced in length from clashing during shifting
should be replaced.
6. Check axial clearances of gears. Where excessive clear•
ance 1s found. check gear retaining ring, washer, spacer and
gear hub excessive wear. Maintain .005" to .012" axial clear-
ance on mainshaft forward speed gears .. 005" minimum on
reverse gear.
7, Check splines on all shafts for wear. If sliding clutch gears.
companion flange or clutch hub have worn into the sides of the
splines. the shafts in this condition should be replaced.
8. Check surfaces of all thrust washers. Washers scored or
r.educed in thickness should be replaced.
9. Check bearing sleeve for wear from action of roller
bearings.
10. Inspect all gray iron parts for cracks and breaks. Replace
or repair parts found to be damaged. Heavy castings may be
welded or brazed providing the cracks do not extend into bear-
ing bores or bolting surfaces.
11. Check clutch release parts. Replace yokes worn at cam
surfaces and bearing carrier worn at contact pads.
12. Check pedal shafts. Replace those worn at bearing
surfaces.
13. Check yokes and blocks for wear at pads and lever slot.
Replace worn parts.
14. Check yokes for alignment. Straighten those which are
sprung.
15. Check lockscrews in yokes and blocks. Tighten and
rewire those found loose.
16. If housing has been dismantled, inspect neutral notches
oi shifting bars for wear from interlock balls. Bars indented at
points adjacent to the neutral notch should be replaced.
17. Check pivot pin and corresponding slot in lever for wear.
Replace both parts if wom.
18. Check covers for wear from thrust of adjacent bearing.
Replace covers worn and grooved from thrust of bearing outer
race.
19. Check bores of covers for wear. Replace those worn
oversize.
20. Check oil return threads in front bearing ·cover. If sealing
action of threads has been destroyed by contact with input
shatt, replace the cover.
21. Check oil seal in rear bearing cover. If sealing action of
lip has been destroyed, replace seal.
REASSEMBLY
CAUTION: Make sure that interiors of case
and housings are clean. It is important that
dirt be kept out of transmission during
reassembly. Dirt is abrasive and can dam-
age polished surfaces of bearings and
washers.
Use new gaskets throughout the transmission as it is being
rebuilt. Make sure all gaskets are installed, as omission of a
gasket can result in oil leakage or misalignment of bearing
covers.
To prevent oil leakage, use shellac on all capscrews.
Coat all thrust washers and splines of shafts with Lubriplate
during installation to provide initial lubrication, preventing scor-
ing and galling.
Use of flanged-end bearing drivers is recommended for the
installation of bearings. These drivers apply equal force to both
races of bearing, preventing damage to balls and races and
maintaining correct bearing alignment with shaft and bore. If
tubular or sleeve type driver is used, apply force only to inner
race.
Pull the companion flange tightly into place with the output
shaft nut. tightening to 400-450 ft. ibs. (542-610 Nm) torque. Be
sure that the spacer has been installed on the yoke. Failure to
pu II the yoke or flange tightly into place will permit the shaft to
move axially with resultant damage to rear bearing. Figure
13:.59 shows the transmission parts in an exploded view.
TIMING
Timing is mentioned at various points in subsequent pages
dealing with the transmission reassembly and installation. It is
recommended that the procedures pertaining to timing, which
are given below, be refe~red to whenever timing is involved.
It is essential that proper timing procedures are carried out
during reassembly and installation. Proper timing assures that
the countershaft gear teeth will come into contact with the
mating mainshaft gear teeth at the same time, allowing the
mainshaft gears to center on the mainshaft and split the load
between the countershaft gear assemblies. If improperly timed.
however, the mainshaft gears would climb out of equilibrium,
resulting in unequal tooth contact between meshing gears that
would lead to more serious damage occurring to the transr:iis-
sion later.
By design, the timing of only one set of gears is necessary -
the drive gear set. It is a rather simple procedure, consisting of
marking the proper teeth of the main and countershaft drivt
gears prior to installation of the complete assemblies in the
case and meshing those marked gear teeth during assembly.